en.Wedoany.com Reported - Z-AXIS, an electronics manufacturing services provider based in New York, USA, has resolved capacity bottlenecks and material management issues by upgrading Mycronic equipment and software systems without increasing shifts or team size. The company operates high-mix production at its facility in Phelps, New York, with three SMT lines handling batch sizes ranging from 25 to 4,000 circuit boards, supported by a team of 95 employees. Company President Michael Allen stated that Z-AXIS has been a Mycronic customer for nearly 25 years, and the business environment demands core requirements for flexibility, repeatability, and reliability.
As production demand grew beyond the capacity of existing equipment, Z-AXIS's capacity frequently reached or neared saturation, sometimes requiring Saturday overtime to meet customer needs. Thousands of components flow through the factory each week, with manual material handling creating additional obstacles: operators had to frequently search for missing reels, manage inconsistent residual inventory, and face unexpected downtime lasting hours due to material shortages. These inefficiencies squeezed capacity, increased operator stress, and threatened customer delivery schedules.
The core of the solution involved introducing next-generation stencil printers, pick-and-place machines, and storage systems that maintained the same operational methods as previous systems but with significantly enhanced performance. Among these, the MYPro A40DX pick-and-place machine, as the core equipment for the new third high-speed line, is designed for speed, precision, and flexibility. After years of downtime issues with competitor printers, Z-AXIS upgraded to multiple Mycronic MYPro S30 stencil printers, whose superior performance led the company to standardize on Mycronic printing technology across all three production lines. All SMT lines use Mycronic interconnect software (TPSys platform), providing a reliable, retrievable unified data set, with production data preparation in MYCenter and integrated planning and scheduling in MYPlan. Automated storage became a turning point for the company; Z-AXIS installed multiple Mycronic component storage systems, eliminating the need to search for reels, enabling precise inventory control, supporting uninterrupted changeovers, and improving inventory handling processes.
"When we ran our first large order on the A40, we found that work that normally took three days was completed in just two—it was impressive," said Z-AXIS President Michael Allen.
The deployment of new equipment spanned several years across multiple phases. Each upgrade—from MY9 to MY200, MY300, and finally to MYPro A40DX—maintained compatibility with the same feeders, bins, and operating concepts, minimizing training needs. As capacity demand grew, Z-AXIS added a complete high-speed line driven by two MYPro A40DX pick-and-place machines, immediately boosting throughput and providing the team with a buffer to support sustained growth of 15%–20% per year. After testing one MYPro S30, Z-AXIS replaced the remaining printers, as the MYPro S30 system delivered significantly higher print quality, reliability, and lower downtime. The installation of four Mycronic automated storage towers resolved long-standing inventory accuracy issues and enabled a clear first-in, first-out workflow, with automatic dispensing, replenishment, and reel retrieval eliminating hours previously wasted searching for parts.
"Automated tower storage has completely transformed our material management. We no longer waste time searching for reels or organizing partial inventory—everything is orderly, traceable, and available when needed. This has eliminated a lot of waste and the stress of unexpected downtime," continued Z-AXIS President Michael Allen.
Although tariffs and global supply constraints caused minor delays, Z-AXIS emphasized that Mycronic's service team ensured efficient installation. Technicians were professional, knowledgeable, and able to quickly escalate complex issues to global experts when necessary, with answers typically received overnight. Mycronic Regional Sales Manager Liz Morrill stated, "Working with Z-Axis has always been a true partnership. They move fast and demand high efficiency, and our job is to show up when they need us. Whether it's a quick answer or coordinating a smooth escalation, we ensure they receive uninterrupted support."
Z-AXIS found that multiple operational factors played a significant role in improving SMT efficiency and stabilizing overall production costs. Faster pick-and-place machines increased throughput, allowing the company to expand output without adding extra personnel or shifts. Automated material handling significantly reduced time previously wasted searching for missing reels and resolved inventory inconsistencies. Real-time part tracking and proactive replenishment further reduced unexpected downtime that could halt production lines for hours. These improvements collectively enhanced SMT efficiency and operational cost control.
After each Mycronic equipment upgrade, Z-AXIS's production lines saw clear results. Jobs were completed faster, parts were easier to manage, and the team could focus on assembling circuit boards rather than searching for materials or dealing with delays. The combination of the MYPro A40DX pick-and-place system, MYPro S30 stencil printers, and automated MYTower storage helped them maintain pace as production batches became more complex and high-mix. With faster machines, reliable storage, and fewer interruptions, Z-AXIS was able to keep up with steady growth while maintaining on-time delivery.
